Inspection After Disassembly
INSPECTION AFTER DISASSEMBLYShift Control
If the contact surface on striking lever, fork rod, shift fork, etc., has excessive wear, abrasion, bend, or any other damage, replace the components.
Gear and Shaft
If the contact surface on each gear, mainshaft, main drive gear, and counter gear, etc., has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.
Synchronizer
^ If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components.
^ Coupling sleeve and synchronizer hub shall move smoothly.
^ If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
^ If spread spring damaged, replace with a new one.
Baulk Ring Clearance
^ Single Cone Synchronizer (5th and 6th)
Push baulk ring on the cone, and measure the clearance between baulk ring and cone. If the measurement is below limit, replace it with a new one.
Clearance
Standard value: 0.7 - 1.35 mm (0.028 - 0.0531 inch)
Limit value: 0.5 mm (0.020 inch)
^ Double Cone Synchronizer (1st, 3rd and 4th)
Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.
CAUTION: The clearances A and B are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.
1. Measure the clearance A at 2 points or more diagonally opposite using a dial indicator and Tool. Then calculate the mean value.
Clearance "A"
Standard value 0.5 - 0.7 mm (0.020 - 0.028 inch)
Limit value: 0.3 mm (0.012 inch)
2. Measure the clearance B at 2 points or more diagonally opposite using a feeler gauge. Then calculate the mean value.
Clearance "B"
Standard value 1st: 1.0 - 1.5 mm (0.039 - 0.059 inch)
3rd, 4th: 0.85 - 1.35 mm (0.0335 - 0.0531 inch)
Limit value: 0.7 mm (0.028 inch)
^ Triple Cone Synchronizer (2nd)
Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.
CAUTION: The clearances "A", "B" and "C" are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.
1. Measure the clearance "A" at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the mean value.
Clearance "A"
Standard value: 0.6 - 1.3 mm (0.024 - 0.051 inch)
Limit value: 0.3 mm (0.012 inch)
2. Measure the clearance B at 2 points or more diagonally opposite using a feeler gauge. Then calculate the mean value.
Clearance "B"
Standard value: 0.85 - 1.35 mm (0.0335 - 0.0531 inch)
Limit value: 0.7 mm (0.028 inch)
3. Measure the clearance "C" at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the mean value.
Clearance "C"
Standard value: 0.7 - 1.25 mm (0.028 - 0.0492 inch)
Limit value: 0.3 mm (0.012 inch)
^ Reverse Synchronizer
Push baulk ring on the cone, and measure the clearance between baulk ring and cone. If the measurement is below limit, replace it with a new one.
Clearance
Standard value: 0.75 - 1.2mm (0.0295 - 0.047 inch)
Limit value: 0.5 mm (0.020 inch)
Bearing
If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.